Pad and fabric arrangement and method of making the same

ABSTRACT

A pad arrangement comprises a layer of fabric with a pad connected to the layer of fabric. The pad includes a plurality of energy absorbing structures. Each of the plurality of energy absorbing structures includes an outer surface connected to the layer of fabric. Each of the outer surfaces is spaced apart from other outer surfaces on the pad. A plurality of buttresses extend between the energy absorbing structures, each of the plurality of buttresses extending downwardly and away from the outer surface of one or more of the energy absorbing structures.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent document is a continuation of U.S. patent application Ser.No. 13/012,532, filed Jan. 24, 2011, which claims priority from U.S.provisional application No. 61/297,687, filed Jan. 22, 2010, the entirecontents of which are incorporated herein by reference.

FIELD

This patent document relates to the field of padding arrangements andparticularly to padding arrangements for use on athletic garments andother apparel.

BACKGROUND

Padding is commonly used on athletic garments and other apparel toprotect the human body. This is especially true in contact sports, suchas football, where athletes commonly wear pads to protect soft tissueand other areas of the body. Such pads include, for example, hip pads,thigh pads, knee pads, and other pads worn in association with theuniform. These pads protect the athletes from impacts experienced duringa game or practice.

Athletic pads carried by garments have traditionally been removeablyinserted into pockets provided on the garment in order to hold the padsin place. For example, football hip pads have traditionally beeninserted into hip pockets on football pants. After the pants are worn,the pads are removed before the pants are washed. However, removablepads are inconvenient since they must be inserted and removed from thepockets before and after use. In addition, such pads may be easily lostor misplaced between wearings, thus forcing the wearer to findreplacement pads. To avoid these issues, many pads are now permanentlyattached to garments. In particular, in many modern athletic garments,pads are permanently sewn into closed pockets provided on the garmentand/or fastened to the garment with adhesives or welding.

Pads that are permanently attached to garments are repeatedly subjectedto various stresses. Because the pads are permanently positioned on thegarments, they must be capable of withstanding repeated exposure towater, cleansers and heat during washing and drying cycles.Additionally, when the pads are worn during an athletic event they aresubjected to further stress. For example, movement of the athlete causesthe pads to repetitively bend, subjecting the pads to stresses that maycause tearing or other damage to the pads. This is especially true ifthe pads are worn in a major muscle or joint area, such as a knee pad.Pads worn during an athletic event will also be subjected to variousstresses from impacts to the pads during the athletic event.

Typical athletic pads are often a simple sheet of foam material cut intoa particular shape that covers a certain body area where protection isdesired. These traditional pads are not ideal for withstanding thestresses associated with athletic garments. First, these traditionalpads are not highly durable and designed to withstand repeated washingand exposure to water and heat of levels that occur in elite athletics.Second, when these traditional pads are bent during athletic activity,the pad experiences surface stress that may reduce the flexibility ofthe pad.

In view of the foregoing, it would be desirable to provide an improvedpadding arrangement that may be used in association with an athleticgarment. It would be advantageous for such padding arrangement to beflexible and capable of conforming to the athlete during wear. It wouldalso be advantageous if such padding arrangement were highly durable andcapable of withstanding repeated washing and drying cycles in additionto repeated flexing and bending. Furthermore, it would be advantageousfor such padding arrangement to provide a high level of protection fordesignated areas on the human body.

SUMMARY

In accordance with one embodiment of the disclosure, there is provided apad arrangement comprising a layer of fabric and a pad connected to thelayer of fabric. The pad includes a plurality of energy absorbingstructures. Each of the plurality of energy absorbing structuresincludes an outer surface connected to the layer of fabric. Each of theouter surfaces is spaced apart from other outer surfaces of the energyabsorbing structures on the pad. A plurality of buttresses extendbetween the energy absorbing structures, each of the plurality ofbuttresses extending downwardly and away from the outer surface of oneor more of the energy absorbing structures.

At least one related embodiment of the disclosure involves a method ofmanufacturing a pad arrangement. The method of manufacturing the padarrangement comprises providing a sheet of energy absorbing materialhaving a first side and a second side. A cutting tool is used to cutinto the first side of the sheet to form a plurality of energy absorbingmembers with buttresses extending between the energy absorbingstructures. Each of the energy absorbing structures is defined by anouter surface, and the outer surfaces are separated from each other onthe cut sheet of energy absorbing material. Each of the plurality ofbuttresses extends downwardly and away from the outer surface of one ormore of the energy absorbing structures. The method further comprisesconnecting a layer of fabric to the outer surfaces of the energyabsorbing structures. The layer of fabric may be comprised of an elasticmaterial such that the fabric stretches between the outer surfaces ofthe energy absorbing structures when the pad flexes.

In accordance with yet another embodiment of the disclosure, there isprovided a pad arrangement comprising a layer of fabric and a padadjacent to the layer of fabric. The outer surface of the pad includes aplurality of protuberances with each of the protuberances including afabric engaging surface extending to the layer of fabric. The fabricengaging surfaces are spaced apart from each other on the pad, and aplurality of support structures extend between and interconnect theprotuberances. Each of the plurality of support structures extendsdownwardly and away from one or more of the fabric engaging surfaces.

The above described features and advantages, as well as others, willbecome more readily apparent to those of ordinary skill in the art byreference to the following detailed description and accompanyingdrawings. While it would be desirable to provide a padding arrangementthat provides one or more of these or other advantageous features, theteachings disclosed herein extend to those embodiments which fall withinthe scope of any appended claims, regardless of whether they accomplishone or more of the above-mentioned advantages or include one or more ofthe above-mentioned features.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a top view of a sheet of energy absorbing foam material fora padding arrangement;

FIG. 2 shows a perspective view of the foam sheet of FIG. 1;

FIG. 3 shows a cross-sectional view of the foam sheet along line III-IIIof FIG. 1, and also including layers of fabric adjacent to the upper andlower sides of the foam sheet;

FIG. 4 shows a cross-sectional view of the foam sheet along line IV-IVof FIG. 1, including the layers of fabric on the upper and lower sidesof the foam sheet;

FIG. 5 shows the foam sheet of FIG. 1 flexed in a convex manner;

FIG. 6A shows the foam sheet of FIG. 1 flexed in a convex manner with alayer of fabric engaging the outer surface of the foam sheet;

FIG. 6B is a cross-sectional illustration showing how the fabricstretches when the foam sheet of FIG. 4 is flexed;

FIG. 7 shows a front view of a garment with a padding arrangementincluding the foam sheet of FIG. 1 positioned in a closed pocket of thegarment;

FIG. 8 shows an alternative embodiment of the foam sheet of FIG. 1;

FIG. 9 shows another alternative embodiment of the foam sheet of FIG. 1;

FIG. 10 shows yet another alternative embodiment of the foam sheet ofFIG. 1; and

FIG. 11 shows a block diagram for a method of manufacturing a paddingarrangement such as the padding arrangement of FIG. 1.

DESCRIPTION

With reference to FIGS. 1-6, in at least one embodiment, a pad andfabric arrangement 20 comprises a sheet 22 of resilient compressiblematerial with two opposing sides and a layer of fabric 50 engaging thesheet. The two opposing sides of the sheet 22 include an inner side 26configured to face a protected member such as a body part, and an outerside 24 configured to face away from the protected member. A pluralityof energy absorbing structures 30 are formed on the outer side of thesheet 22 of compressible material. The plurality of energy absorbingstructures are interconnected by buttresses 40 that extend between theenergy absorbing structures 30. The energy absorbing structures 30include pods or other protuberances 32 that project outwardly on theouter side 24 of the pad. Each protuberance 32 includes an outer surface34 that is connected to a layer of fabric 50. The pad and fabricarrangement 20 (which may also be referred to herein as a “paddingarrangement” or “pad arrangement”) may be placed in any of variouslocations on a garment where impact protection for the wearer isdesired.

In at least one embodiment, the resilient compressible material for thesheet 22 is provided as a closed cell EVA (Ethylene-Vinyl Acetate) foammaterial (and thus the sheet 22 may also be referred to herein as a“foam sheet” or a “foam pad”). Closed cell EVA foam material does notabsorb water or perspiration and is relatively durable. Even though theresilient compressible material has been disclosed herein as being aclosed cell EVA foam in one embodiment, it will be recognized that theresilient compressible material may be any of numerous differentmaterials in other embodiments. For example, the resilient compressiblematerial could be a polyurethane foam or a polyethylene foam, an opencell foam, EVA, or even a gel material encased in a plastic shell.Therefore, although the sheet of resilient compressible material isdescribed in various embodiments herein as a “foam material” or “foamsheet”, it will be recognized that the resilient compressible materialcould also be a different material other than foam in other embodiments.

In the embodiment of FIGS. 1-6, and as best seen in FIGS. 3 and 4, thesheet of foam material 22 is a two layer sheet including an upper layerof foam material 25 and a lower layer of foam material 27. The upperlayer serves as an outer layer 25 of foam material for the paddingarrangement and the lower layer serves as an inner layer 27 of foammaterial for the padding arrangement. The outer layer 25 and inner layer27 are comprised of different density foam materials, with the outerlayer 25 having a higher density than the inner layer 27. Accordingly,even though both foam layers 25, 27 are generally soft and flexible, theouter layer 25 of the foam sheet 22 is somewhat harder and more rigidthan the inner layer 27. This arrangement provides a harderimpact-resistant layer on the outer portion of the sheet 22, and asofter more comfortable layer on the inner portion of the sheet 22 thatis closer to the skin of the wearer.

The inner surface 26 of the foam sheet is substantially flat and planar,providing a comfortable smooth surface that faces the skin of thewearer. In contrast, the outer surface 24 of the foam sheet is contouredand includes a plurality of protuberances 32 and depressions 38, withridges 42 extending between the protuberances 32. The protuberances 32define the energy absorbing structures 30 on the outer side 24 of thefoam sheet 22. The ridges 42 define the outer perimeter of thebuttresses 40 on the outer side 24 of the foam sheet 22. The ridges 42are oriented in a spoke-like configuration around the protuberances 32such that they extend radially outward from the protuberances. Thedepressions 38 are recessed areas on the outer surface 24 of the foamsheet 22 and are surrounded by the protuberances 32 and the ridges 42.

Each protuberance 32 defines an outer surface 34 configured to engagethe fabric layer 50 (and thus the outer surface 34 is also referred toherein as a fabric engaging surface 34). Each fabric engaging surface 34is generally planar and provides a flat surface area that facilitatesconnection of the protuberance to the outer fabric layer 50. In theembodiment of FIGS. 1-6, the fabric engaging surfaces 34 are generallycircular in shape. However, it will be recognized that in otherembodiments, the fabric engaging surfaces 34 may be differently shaped,such as rectangular or any of various other geometric shapes. Althoughthe term “fabric engaging surface” is used herein to refer to thesurface that serves to connect the outer fabric layer 50 to the foamsheet, it will be recognized that in some embodiments the fabricengaging surfaces may not come into direct contact with the fabric layer50, such as when an adhesive layer is used to join the two surfaces, butmaintains some separation between the surfaces. Therefore, the term“fabric engaging surface” as used herein is not limited to a surfacethat actually contacts a fabric layer, but is intended to refer to asurface that is directly joined to a fabric layer using some fasteningmeans, such as an adhesive, regardless of whether the surface actuallycontacts the fabric.

With specific reference now to FIGS. 3 and 4, cross-sectional views ofthe pad of FIG. 1 are shown with an outer fabric layer 50 connected tothe outer surface 24 of the foam sheet 22 at the fabric engagingsurfaces 34. An inner fabric layer 52 is also shown adjacent to theinner surface 26 of the foam sheet. However, in the disclosedembodiment, the inner surface 26 of the foam sheet is not directlyconnected to the inner fabric layer 52. Thus, the inner fabric layer 52is freely moveable relative to the inner surface 26 of the foam sheet22.

In FIGS. 3 and 4, the side boundaries of the energy absorbing structures30 are noted with dotted lines that extend perpendicularly from theperimeter of the fabric engaging surfaces 34. Each energy absorbingstructure 30 extends inward on the pad 22 from the associated fabricengaging surface 34, as noted by the dotted lines, and defines apillar-like portion of the pad, with the pillar-like portion of the padhaving a cross-sectional shape that is the same shape as the associatedfabric engaging surface 34. As mentioned previously, the energyabsorbing structures 30 form protuberances 32 on the outer side 24 ofthe foam sheet. The buttresses 40 interconnect the energy absorbingstructures 30 on the outer side of the foam sheet. On the inner side 26of the foam sheet, the energy absorbing structures are interconnected bya common foam base portion 36.

With continued references to FIGS. 3 and 4, it can be seen that theouter surfaces 34 (i.e., the fabric engaging surfaces) of the energyabsorbing structures 30 are separated from one another and generallyspaced apart. However, the energy absorbing structures themselves 30 areall interconnected by the buttresses 40 and the base portion 36 of thefoam sheet. The base portion 36 of the foam pad is generally continuousand uninterrupted, as shown in the cross-sectional view of FIG. 4.However, as shown in the cross-sectional view of FIG. 3, the pad mayinclude a plurality of holes or bores 48 that extend partly orcompletely through the sheet of foam material 22, including the baseportion 36. As explained in further detail below, these holes 48 serveas air vents for the pad arrangement.

As shown in FIGS. 3 and 4, the buttresses 40 extend between the energyabsorbing structures 30 on the foam sheet 22 and act as supportstructures that provide stability and support for the energy absorbingstructures 30. The buttresses 40 are integral with the cylindrical wallsof the energy absorbing structures 30 and are comprised of the samematerial as the energy absorbing structures. In the embodiment of FIGS.1-6 the buttresses 40 curve downward and away from the side wall of oneenergy absorbing structure 30, into a saddle point 44, and then back upand toward the side wall of another energy absorbing structure. Thus, inthis embodiment, the ridges 42 of the buttresses 40 are concave in shapeon the outer surface 24 of the foam sheet 22. Although one form for thebuttresses is shown in the embodiment of FIGS. 1-6, it will berecognized that the buttresses may be provided in different forms inother embodiments of the padding arrangement 20.

In addition to energy absorbing structures 30 and buttresses 40, thefoam sheet 22 includes a plurality of cuts 60 that facilitate flexing ofthe sheet. In the embodiment of FIGS. 1-6 the foam sheet 22 includesthree sets of directional slits 60 provided as score lines. As best seenin FIG. 1, the score lines include a set of first axial score lines 62,a set of second axial score lines 64, and a set of third axial scorelines 66. Each score line 60 of one set is angled relative to a scoreline from another set by about forty-five to ninety degrees, andparticularly about sixty degrees in at least one embodiment. While theembodiment of FIGS. 1-6 shows three sets of axial score lines atapproximate sixty degree angles, it will be recognized that numerousother configurations for the score lines 60 are possible, including thescore lines 60 in the embodiment shown in FIGS. 8-10. Furthermore, in atleast one embodiment, five sets of axial score lines oriented indifferent directions may be provided in the foam sheet.

The score lines 60 generally cut into the buttresses 40 without cuttinginto the fabric engaging surfaces or the associated energy absorbingstructures. In addition, as shown by the score lines 60 in thecross-sectional view of FIGS. 3 and 4, the score lines 60 extend throughthe outer layer 25 of the foam sheet but do not cut completely throughthe inner layer 27 foam sheet (i.e., the cuts do not extend to the innersurface 26 of the foam sheet).

The score lines 60 form small gaps in the upper portion of the foamsheet 22 that allow the protuberances 32 to move away from one anotherwithout ripping the outer surface 24 of the foam sheet 22. Therefore,the score lines or other cuts on the foam sheet provide for a padarrangement with increased flexibility. The pad arrangement 20 may beplaced on a garment in the vicinity of a human limb or other body part,and easily flexed to conform to the shape of the body part.Alternatively, if the pad arrangement is place on a garment in thevicinity of a muscle or human joint, the pad may be repeatedly flexedduring movement of the wearer without damage to the pad. If the foamsheet 22 is provided with a sufficient number of directional score lines60, the foam sheet may be flexed to cover a hemispherical orsemi-hemispherical member without damage to the sheet. This allows thefoam sheet 22 to be bent to cover the substantial portion of a majormuscle area or a human joint. When the foam sheet 22 is flexed as shownin FIG. 5, the ridges 42 of the buttresses 40 split apart at thelocation of the score lines 60, creating relatively large cavities orgaps in the foam sheet in the area of the buttresses. However, becausethe score lines 60 do not extend completely through the inner layer 27of the foam sheet 22, the foam sheet remains a unitary piece even duringflexing.

As mentioned previously, the foam sheet 22 may include a plurality ofbore holes 48 that extend partly or completely through the foam sheet.These holes 48 generally provide passages that allow the foam sheet tobreathe by passing air from the inner surface of the foam sheet to theouter surface of the foam sheet and vice-versa. In the embodiment ofFIGS. 1-6, the air passages 48 are only provided in the inner layer 27of foam material. Thus, as shown in FIGS. 3 and 4, the air passages donot extend through those parts of the pad that are covered by the outerlayer 25 and the associated fabric engaging surfaces 34. This reservesthe entire surface area of each fabric engaging surface 34 forconnection to the outer layer 50 of fabric.

In the embodiment of FIGS. 1-6, the outer layer of fabric 50 iscomprised of a stretchable material such as elastane. As best seen inFIGS. 3, 4 and 6, the outer layer of fabric 50 completely covers theouter surface 24 of the foam sheet 22, but is only directly connected tothe outer surface 24 of the foam sheet at the fabric engaging surfaces34. Portions of fabric 50 that are not immediately adjacent to thefabric engaging surfaces 34 extend over but are not directly connectedto the buttresses 40 and the depressions 38 on the outer surface 24 ofthe foam sheet 22. The layer of fabric 50 is fixedly connected to thefabric engaging surfaces 34 of the foam sheet 22 using an adhesive, suchas a thermal plastic adhesive. In other embodiments, the fabric engagingsurfaces 34 may be connected to the fabric 50 using other types ofadhesives, a weld, or any other suitable fastening means. As mentionedpreviously, the means used to connect the fabric 50 to the fabricengaging surfaces 34 may result in all or part of the fabric engagingsurfaces 34 being out of direct contact with the fabric 50. For example,if a thick adhesive is used to connect the fabric 50 to the fabricengaging surfaces 34, the adhesive may keep the fabric slightlyseparated from the fabric engaging surfaces while still providing adirect connection between the fabric 50 and the fabric engaging surfaces34.

When the foam sheet 20 is flexed, as shown in FIGS. 5, 6A and 6B, thebase of the cuts 60 act as a hinge and the protuberances 32 diverge. Atthe same time, portions of the outer fabric layer 50 that are directlyconnected to fabric engaging surfaces 34 remain connected to and movewith the fabric engaging surfaces. The elastic quality of the fabric 50allows the free portions of fabric between the fabric engaging sections34 to stretch when the fabric engaging sections are moved relative toone another. This allows the pad to flex easily. Thereafter, when aforce causing the foam sheet 20 to flex is removed (e.g., when a the padis removed from the human, when a muscle is relaxed or when a joint isstraightened), the elastic quality of the fabric 50 draws the fabricengaging sections 34 back together such that the foam sheet 22 retainsits original shape.

With reference now to FIG. 7, the padding arrangement 20 may be fastenedto or otherwise positioned on any portion of a garment where impactprotection is desired. For example, the padding arrangement 20 may beprovided on a bicep portion 72 or rib portion 74 on a shirt 70, or on ahip area 82 or thigh area 84 on pants 80. In other possible embodiments,the foam pad may also be placed in any other desired locations on agarment, such as elbow areas, forearm areas, knee areas, or any otherarea where protection is desired. With reference to FIGS. 3 and 4, thefoam pad 22 is generally secured on a garment by placing the foam sheetbetween an outer fabric layer 50 and an inner fabric layer 52. The innerand outer fabric layers are connected outside the perimeter of the foamsheet to trap the foam sheet in place on the garment. In other words,the inner and outer fabric layers form a closed pocket for the foamsheet which secures the foam sheet 22 to the garment. In the embodimentof FIGS. 1-6, the foam sheet 22 is directly connected to the outerfabric layer 50 using the fabric engaging surfaces 34 on the outer side24 of the foam pad. The inner side 26 of the foam pad may also bedirectly connected to the inner fabric layer 52. Again, with thisconfiguration, when the sheet 22 is flexed outwardly, the areas on theouter fabric layer 50 between the fabric engaging surfaces 34 arestretched, as noted by arrow 51 in FIG. 6B. Other portions of the outerfabric layer 50 are directly adhered to the fabric engaging surfaces 34and remain fixed to the fabric engaging surface 34 during the flexevent.

While one connection arrangement for the foam sheet 22 to the fabriclayers has been disclosed with reference to FIGS. 1-6, it will berecognized that in other embodiments, a different arrangement may beused to connect the foam sheet 22 to the fabric layers. For example, inother embodiments, the foam sheet 22 could be directly connected toeither the inner fabric layer or the outer fabric layer and not directlyconnected to both layers. In another embodiment, the foam sheet may besimply trapped in a pocket formed by the layers 50 and 52 and notdirectly connected thereto. Also, various means may be used to connectthe foam sheet to the fabric layers, such as an adhesive, weld or otherconnection arrangement. In yet another embodiment, the foam sheet may besewn in place in the pocket on the garment.

A garment 18 including the padding arrangement 20 described herein willremain pliable and drapable even with the padding arrangement secured tothe garment. In particular, the cuts 60 in the foam sheet 22 allow thefoam sheet to flex in a convex manner such that the protuberances on theouter surface of the foam sheet move away from each other. An example ofsuch convex flexing is when the padding arrangement 20 is flexed by abent joint or around a limb. Furthermore, because the foam sheet 22 iscompressible, the outer surfaces of the protuberances may also be movedcloser to one another when the foam is flexed in a concave manner. Anexample of such concave flexing is when an outside force impacts thepadding arrangement. The fabric 50, 52 that surrounds the paddingprotects the foam sheet 22 from abrasion and dirt and ultimately holdsthe padding in place on the garment both during and after wear.

The padding arrangement 20 disclosed herein provides for a plurality ofenergy absorbing structures that are interconnected as a single unitfoam sheet. At the same time, the fabric engaging surfaces 34 on theouter surface of the foam sheet are separated from one another. When animpact is delivered to the padding arrangement during an athletic eventor other activity, the impact is received by the energy absorbingstructures 30 and the large base 36 of foam material connecting theenergy absorbing structures acts to dissipate the impact over a largearea. The foam padding has significant flexibility resulting from thecuts in the foam sheet in combination with the pods 32 on the outersurface of the foam sheet. Moreover, the material used for the foampadding makes it highly durable and wear resistant.

FIG. 8 shows one alternative embodiment of the padding arrangement 20.In this alternative embodiment, the sheet of foam material 22 is only asingle layer of foam. There are fewer bores 48 through the foam sheet 22in this embodiment than in the embodiment of FIGS. 1-6, but the bores inthe embodiment of FIG. 8 are larger and are positioned in thedepressions 38. Similar to the embodiment of FIGS. 1-6, the buttresses40 form ridges 42 that extend between the energy absorbing structures30. Also, three sets of axial score lines 62, 64, 66 are cut into thefoam sheet.

FIG. 9 shows another alternative embodiment of the padding arrangement20. In this alternative embodiment, the sheet of foam material 22 iscomprised of two foam layers of different densities, similar to theembodiment of FIGS. 1-6. However, in this embodiment, the bore holes 48are larger, similar to the embodiment of FIG. 8, and are positioned inthe depressions 38. In addition, the score lines 60 in the embodiment ofFIG. 9 are short score lines that only extend between the bore holes 48.This is in contrast to the elongated score lines of the embodiments ofFIGS. 1-6 and 8. The score lines 60 in the embodiment of FIG. 9 cutacross the buttresses 40, but do not cut into the protuberances 32 orthe related fabric engaging surfaces 34.

FIG. 10 shows yet another alternative embodiment of the paddingarrangement 20. This alternative embodiment also includes a two layersheet of foam material 22, larger bore holes 48, and score lines 60 thatextend between the bore holes 48, similar to the embodiment of FIG. 9.However, in the embodiment of FIG. 10, the bore holes 48 are triangularin shape and two score lines 60 cut into each buttress 40. Furthermore,in the embodiment of FIG. 10, the outer layer 25 of foam sheet 22 doesnot cover the entire length of each ridge 42. Instead, the saddle point44 of each ridge 42 is positioned on the inner layer 27 of the foamsheet 22. The dual score lines 60 on the buttresses 40 only cut into theinner layer 27 of the foam sheet and do not cut into the outer layer 25closer to the fabric engaging surfaces 34.

The above alternative embodiments are only a few of the numerouspossible alternative embodiments for the padding arrangement 20. Forexample, in another alternative embodiment, the foam sheet may be amulti-layer foam sheet with at least three layers of foam, and each foamlayer having a different density. In this embodiment, the inner foamlayer is provided closest to the skin of the wearer and is the leastdense. A middle foam layer is connected to the inner layer and is denserthan the inner layer. The outer foam layer is furthest from the body ofthe wearer and provides the densest layer. This padding arrangementcreates a relatively hard impact-resistant outer layer that includes thefabric engaging surfaces. During athletic activity, contact to the padoccurs first on this impact-resistant outer layer and the force of suchcontact is then distributed to the other foam layers. The softest foamlayer is provided next to the skin for comfort.

With reference now to FIG. 11, a method of manufacturing the paddingarrangement 20 is disclosed. The method begins with action 110 and theassembly of a sheet of resilient compressible material, such as a sheetof EVA closed cell foam material. The sheet may be a multi-layer sheetor a single layer sheet, depending on the particular embodiment of thepadding arrangement to be manufactured. If the sheet is a multilayersheet, the individual layers are first connected together using anadhesive or other bonding method to form a unitary sheet with tworelatively smooth and flat sides. If one of the layers will include airvents or other holes, such as that shown in the embodiment of FIGS. 1-6,such holes may be pre-formed by passing the layer of foam materialthrough a die before assembly of the multi-layer foam sheet. Thus, whenmanufacturing the foam sheet in the embodiment of FIGS. 1-6, the secondlayer may be pre-cut to include the plurality of air holes before thesecond layer is secured to the first layer.

The assembled foam sheet is generally a rectangular sheet of materialthat is relatively large compared to the size of the final foam paddingarrangement. For example, the foam sheet may be about 1 to 5 feet inwidth and relatively long, such as ten feet or more in length. In atleast one embodiment, the foam sheet may be a roll of foam material of50 feet or more in length. However, it will be recognized that foamsheets of various different sizes may be used according to the disclosedmethod of manufacture.

The thickness of the foam sheet is generally greater than a quarter inchbut less than an inch. This thickness allows the eventual paddingarrangement to provide a desired degree of protection while stillmaintaining significant flexibility. However, it will be recognized thatfoam sheets of different thicknesses may be used according to thedisclosed manufacturing process.

After the foam sheet is assembled in the action 110, contours are cutinto one side of the foam sheet in action 120. This cutting process isgenerally performed by passing the entire foam sheet through a cuttingstation where the surface of the foam sheet is cut. This first cuttingaction 120 results in a foam sheet having a contoured outer surface thatdefines energy absorbing structures with buttresses extending betweenthe energy absorbing structures. In at least one embodiment, thecontoured outer surface includes a repeating pattern of protuberances,ridges and depressions, as described above with reference to theembodiment of FIGS. 1-6. The first cutting action may be performed by askiving process or any other appropriate cutting process capable ofcutting the foam sheet into the desired shape. In other embodiments suchas where the pad arrangement is formed from EVA or other polymermaterial, the cuts could be formed in a mold during an injection moldingprocess without having to make physical cuts. Alternatively, in theseembodiments the cuts could also be made following the molding processusing the above-describe cutting action or another cutting action.

After action 120, the foam sheet is cut again in action 130 to form thedirectional slit cuts in the foam sheet. This second cutting process 130may be performed using kiss cuts that extend into the foam sheet, butnot completely through the foam sheet. As described above with referenceto FIGS. 1-6, the kiss cuts form a plurality of different directionalscore line cuts in the foam sheet, thus allowing the sheet to easilyflex along numerous axes. Although a kiss cut process has been describedherein to form the score lines, it will be recognized that any ofnumerous other cutting processes may be used to produce the score lines.Furthermore, although the formation of the score lines has beendescribed herein as a second cutting action, it will be recognized thatthis cutting process could also be performed first or simultaneouslywith the surface contouring action of block 120.

As noted in block 140 yet another cutting action may be used to formbores in the foam sheet that serve as air vents. This action isgenerally performed using a die, a punch or any other process capable ofcutting completely through the foam sheet to form bore holes with thedesired shape. Again, although this action 140 has been described inaddition to the contouring and kiss cut actions of blocks 120 and 130,it will be recognized that this action may also be performed before orsimultaneously along with the other actions.

In the embodiment of FIG. 11, after the foam sheet has been fully cut,including surface contouring cuts, slit cuts, and bore cuts, an adhesivematerial, such as a thermal plastic adhesive, is applied to the fabricengaging surfaces on the foam sheet. However, it will be recognized thatin other embodiments the adhesive material is applied to the foam sheetbefore it is cut. In this embodiment, action 150 would occur beforeaction 140.

Once the foam sheet with adhesive is formed, a layer of fabric is thenadhered to the contoured outer surface of the foam sheet, as noted inbox 155 of FIG. 11, using the adhesive material. The fabric connected tothe outer layer of the foam sheet is generally a stretch fabriccomprised of elastane. In order to connect the fabric layer to the foamsheet, the fabric layer is first spread over the foam sheet such thatthe fabric contacts the adhesive on the fabric engaging surfaces. Theadhesive is then cured to fix the fabric in place on the foam sheet.Although a thermal plastic adhesive is disclosed herein to connect thefabric layer to the foam sheet, it will be recognized that any ofvarious methods and means may be used to connect the fabric to the foamsheet. Examples of such additional means and methods include epoxymaterials and welds.

Once the fabric layer is connected to the foam sheet, the entire foamsheet is passed under a die that cuts the sheet into desired pad shapes,as noted in block 160 of FIG. 11. For example, one die may be used tocut the foam sheet into pads with a perimeter shape appropriate for kneepads. Another die may be used to cut the foam sheet into pads with aperimeter shape appropriate for thigh pads. After the pads are cut totheir desired shape in action 160, they fall freely from the remainderof the foam sheet and are transported to a bin containing similar shapedpads.

After the pads are cut into desired perimeter shapes in action 160, theyare incorporated into garments, as noted in block 170 of FIG. 11. Whenincorporating a pad into a garment, the perimeter of the fabric on theouter layer of each pad is sewn or otherwise connected to the garment.This creates a closed pocket on the garment which contains the pad. Asdiscussed previously, the inner layer of the pad shaped sheet of foammaterial may be directly connected to the inner fabric layer that formsthe garment. This connection may be made by any of various means,including use of an adhesive, a bonding process, or other known methodsfor joining the pad to the fabric.

In at least one alternative embodiment, the outer fabric layer may beconnected to the foam sheet after the foam sheet has been cut into padshapes. In this embodiment, the outer fabric layer is pre-cut to thesame shape as the pad, but with a slightly larger perimeter. The fabriclayer is then connected to the outer surface of the foam sheet with theperimeter of the fabric layer overlapping the shaped perimeter of thefoam sheet. The overlapping perimeter of the pad may then be easilyconnected to the garment in a desired location.

The foregoing detailed description of one or more embodiments of the padand fabric arrangement has been presented herein by way of example onlyand not limitation. Moreover, there are advantages to individualadvancements described herein that may be obtained without incorporatingother aspects described above. Therefore, the spirit and scope of theappended claims should not be limited to the description of thepreferred embodiments contained herein.

What is claimed is:
 1. A pad arrangement comprising: a layer of fabric;and a pad connected to the layer of fabric, the pad including aplurality of energy absorbing structures, each of the plurality ofenergy absorbing structures including an outer surface connected to thelayer of fabric, each of the outer surfaces spaced apart from each otheron the pad with a plurality of buttresses extending between the energyabsorbing structures, wherein each of the plurality of buttressesextends downwardly and away from the outer surface of one or more of theenergy absorbing structures.
 2. The pad arrangement of claim 1 furthercomprising a plurality of slits in the buttresses, the slits configuredto facilitate flexing of the pad between the plurality of energyabsorbing structures.
 3. The pad arrangement of claim 1 wherein thelayer of fabric is comprised of an elastic material such that fabricstretches between the outer surfaces of the energy absorbing structureswhen the pad flexes.
 4. The pad arrangement of claim 1 wherein the padcomprises a first energy absorbing material and a second energyabsorbing material, wherein the second energy absorbing material has agreater density than the first energy absorbing material.
 5. The padarrangement of claim 4 wherein the buttresses are comprised of the firstenergy absorbing material and the outer surfaces of the energy absorbingstructures are comprised of the second energy absorbing material.
 6. Thepad arrangement of claim 4 wherein the first energy absorbing materialand the second energy absorbing material are both a foam material. 7.The pad arrangement of claim 6 wherein the first energy absorbingmaterial and the second energy absorbing material are both a closed cellfoam material.
 8. The pad arrangement of claim 1 wherein the layer offabric is a first layer of fabric and the pad is positioned between thefirst layer of fabric and a second layer of fabric adjacent to anopposite side of the pad from the first layer of fabric.
 9. The padarrangement of claim 8 wherein the opposite side of the pad is notconnected to the second layer of fabric.
 10. The pad arrangement ofclaim 1 further comprising a plurality of holes extending through thepad and positioned between the plurality of buttresses and the pluralityof energy absorbing structures.
 11. A pad arrangement comprising: alayer of fabric; and a pad adjacent to the layer of fabric, the padincluding, a plurality of protuberances, each of the protuberancesincluding a fabric engaging surface engaging the layer of fabric, eachof the fabric engaging surfaces spaced apart from each other on the pad,and a plurality of support structures comprising concave ridgesextending between the protuberances, the layer of fabric covering thesupport structures without contacting the support structures.
 12. Thepad arrangement of claim 11 further comprising a plurality of gaps inthe support structures, the plurality of gaps configured to facilitateflexing of the pad at the support structures.
 13. The pad arrangement ofclaim 12 wherein the plurality of gaps include a plurality of slitsextending into the ridges.
 14. The pad arrangement of claim 13 furthercomprising a plurality of holes extending through the pad, the pluralityof holes positioned between the ridges and the protuberances.
 15. Thepad arrangement of claim 13 wherein the plurality of slits are orientedon the pad along at least three different axial directions.
 16. The padarrangement of claim 15 wherein the plurality of slits are oriented onthe pad along five different axial directions.
 17. A method ofmanufacturing a pad comprising: providing a foam sheet having a firstside and a second side; cutting the first side of the foam sheet to forma plurality of energy absorbing structures with buttresses extendingbetween the energy absorbing structures, each of the energy absorbingstructures defined by an outer surface, and each of the buttressesextending downwardly and away from the outer surface of one or more ofthe energy absorbing structures; and connecting a layer of fabric to theouter surfaces of the energy absorbing structures.
 18. The method ofclaim 17 further comprising cutting the buttresses to provide gaps inthe buttresses, the gaps configured to facilitate flexing of the pad.19. The method of claim 17 wherein the layer of fabric is separated fromthe buttresses extending between the energy absorbing structures. 20.The method of claim 17 wherein the foam sheet includes a first layer offoam and a second layer of foam, the first layer of foam exposed on thefirst side and the second layer of foam exposed on the second side, thefirst layer of foam having a greater density than the second layer offoam.